Manufacturing method of circuit board

ABSTRACT

A manufacturing method of a circuit board including the following steps is provided. A carrier substrate is provided. A patterned photoresist layer is formed on the carrier substrate. An adhesive layer is formed on the top surface of the patterned photoresist layer. A dielectric substrate is provided. A circuit pattern and a dielectric layer covering the circuit pattern are formed on the dielectric substrate, wherein the dielectric layer has an opening exposing a portion of the circuit pattern. The adhesive layer is adhered to the dielectric layer in a direction that the adhesive layer faces of the dielectric layer. The carrier substrate is removed. A patterned metal layer is formed on a region exposed by the patterned photoresist layer. The patterned photoresist layer is removed. The adhesive layer is removed.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of and claims the priority benefit of U.S. application Ser. No. 15/255,150, filed on Sep. 2, 2016, now allowed, which claims the priority benefit of U.S. provisional application Ser. No. 62/309,930, filed on Mar. 17, 2016. The entirety of each of the above-mentioned patent applications is hereby incorporated by reference herein and made a part of this specification.

BACKGROUND OF THE INVENTION Field of the Invention

The invention relates to a manufacturing method of a circuit board, and more particularly, to a manufacturing method of a circuit board fixing a patterned photoresist layer using an adhesive layer.

Description of Related Art

Nano-imprint lithography (NIL) is a technique for manufacturing fine circuits and is extensively applied in the LED and OLED industries. NIL includes pressing a mold prototype having a pattern (generally referred to as mold, stamp, or template) on a photoresist material to mechanically deform the mold prototype so as to precisely transfer a fine pattern. Therefore, once the manufacture of the mold is complete, a fine structure such as a nano structure can be repeatedly molded in a simple manner, and manufacturing costs and the production of harmful waste in the manufacture can be effectively reduced. As a result, NIL has been expected to be applied in various areas in recent years.

However, after NIL transfers a pattern to a photoresist material, comprehensive exposure needs to be performed, and therefore the patterned photoresist layer to be formed and unnecessary residual photoresist material are both exposed to light. As a result, the residual photoresist layer cannot be removed by a developing solution in a simple manner. Therefore, unnecessary residual photoresist material needs to be removed using inductively-coupled plasma (ICP) or reactive ion etching (RIE), such that the photoresist pattern to be formed is readily damaged and the process yield is poor. Moreover, if the thickness of unnecessary residual photoresist material is too great, then the residual photoresist material may not be completely removed using ICP or RIE.

Moreover, since the size of the fine circuit continues to be reduced, the resulting patterned photoresist layer often has the issue of falling or collapsing due to the small size, and therefore process yield is affected.

SUMMARY OF THE INVENTION

The invention provides a manufacturing method of a circuit board in which a patterned photoresist layer is fixed using an adhesive layer.

The manufacturing method of a circuit board of the invention includes the following steps. A carrier substrate is provided. A patterned photoresist layer is formed on the carrier substrate. An adhesive layer is formed on the top surface of the patterned photoresist layer. A dielectric substrate is provided. A circuit pattern and a dielectric layer covering the circuit pattern are formed on the dielectric substrate, wherein the dielectric layer has an opening exposing a portion of the circuit pattern. The adhesive layer is adhered to the dielectric layer in a direction that the adhesive layer faces the dielectric layer. The carrier substrate is removed. A patterned metal layer is formed on a region exposed by the patterned photoresist layer. The patterned photoresist layer is removed. The adhesive layer is removed.

In an embodiment of the manufacturing method of a circuit board of the invention, the adhesive layer is, for instance, removed by applying a mechanical force.

In an embodiment of the manufacturing method of a circuit board of the invention, the adhesive layer is, for instance, a thermal-sensitive adhesive layer, and the method further includes, after the patterned photoresist layer is removed and before the adhesive layer is removed, performing UV irradiation, laser irradiation, or infrared heating on the adhesive layer.

In an embodiment of the manufacturing method of a circuit board of the invention, the method of forming the patterned photoresist layer on the carrier substrate includes the following steps. A photoresist material layer is formed on the carrier substrate. An imprinting process is performed on the photoresist material layer via a stamp. An exposure process is performed on the imprinted photoresist material layer. The stamp is removed.

In an embodiment of the manufacturing method of a circuit board of the invention, the method further includes, after the dielectric layer is formed and before the adhesive layer is adhered to the dielectric layer, forming a conductive seed layer on a portion of the circuit pattern exposed by the opening and on the dielectric layer, and further including, after the adhesive layer is removed, removing the conductive seed layer below the adhesive layer.

The manufacturing method of a circuit board of the invention includes the following steps. A dielectric substrate is provided. A circuit pattern and a dielectric layer covering the circuit pattern are formed on the dielectric substrate, wherein the dielectric layer has an opening exposing a portion of the circuit pattern. An adhesive layer is formed on the dielectric layer, and the adhesive layer seals the opening. A patterned photoresist layer is formed on the adhesive layer, and the patterned photoresist layer exposes the adhesive layer above the opening. The adhesive layer exposed by the patterned photoresist layer is removed. A patterned metal layer is formed on a region exposed by the patterned photoresist layer. The patterned photoresist layer is removed. The adhesive layer is removed.

In an embodiment of the manufacturing method of a circuit board of the invention, the adhesive layer is, for instance, a thermal-sensitive adhesive layer, and the method further includes, after the patterned photoresist layer is formed and before the adhesive layer exposed by the patterned photoresist layer is removed, performing UV irradiation, laser irradiation, or infrared heating on the adhesive layer exposed by the patterned photoresist layer.

In an embodiment of the manufacturing method of a circuit board of the invention, the method further includes, after the patterned photoresist layer is removed and before the adhesive layer is removed, performing UV irradiation, laser irradiation, or infrared heating on the adhesive layer.

In an embodiment of the manufacturing method of a circuit board of the invention, the method further includes, after the dielectric layer is formed and before the adhesive layer is formed, forming a conductive seed layer on a portion of a circuit pattern exposed by the opening and on the dielectric layer, and further including, after the adhesive layer is removed, removing the conductive seed layer below the adhesive layer.

Based on the above, in the invention, a patterned photoresist layer is firmly formed on a film layer below via an adhesive layer, and therefore the patterned photoresist layer can be effectively prevented from falling or collapsing. Therefore, the adhesion of the photoresist material is less influential in the selection of a photoresist material, such that the selection of the photoresist material is more flexible.

In order to make the aforementioned features and advantages of the disclosure more comprehensible, embodiments accompanied with figures are described in detail below.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification. The drawings illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

FIG. 1A to FIG. 1G are cross-sectional schematics of the manufacturing process of a circuit board shown according to the first embodiment of the invention.

FIG. 2A to FIG. 2E are cross-sectional schematics of the manufacturing process of a circuit board shown according to the second embodiment of the invention.

DESCRIPTION OF THE EMBODIMENTS

In each of the embodiments below, a patterned photoresist layer can be firmly located on a film layer below via an adhesive layer. Therefore, when the size of the circuit continues to be smaller, the resulting patterned photoresist layer can be firmly located on a film layer below without the issue of falling or collapsing.

First Embodiment

FIG. 1A to FIG. 1G are cross-sectional schematics of the manufacturing process of a circuit board shown according to the first embodiment of the invention. First, referring to FIG. 1A, a photoresist material layer 102 is formed on a carrier substrate 100. The carrier substrate 100 is, for instance, a glass substrate, a copper clad laminate, a Si laminate, or a ceramic laminate. In the present embodiment, the photoresist material layer 102 is a photoresist material layer curied after UV irradiation, but the invention is not limited thereto. Moreover, in the present embodiment, a release layer 104 can further be formed between the carrier substrate 100 and the photoresist material layer 102. The release layer 104 can facilitate the separation of a patterned photoresist layer formed by the photoresist material layer 102 and the carrier substrate 100 in a subsequent process.

Next, referring to FIG. 1B, an imprinting process is performed on the photoresist material layer 102 via a stamp 106. The stamp 106 has a pattern corresponding to the circuit pattern to be formed. When the stamp 106 is pressed on the photoresist material layer 102, the photoresist material layer 102 can be deformed, such that a pattern is precisely transferred to the photoresist material layer 102. When the imprinting process is performed, a very thin and unavoidable photoresist residue is generally formed between the stamp 106 and the release layer 104. In particular, for the large contact area between the stamp 106 and the release layer 104, the very thin and unavoidable photoresist residue is largely concentrated in the center of the contact region, and the thickness distribution thereof shows a roughly Gaussian distribution from the periphery to the center, as shown in a photoresist residue 102 b in FIG. 2B. Next, an exposure process is performed on the imprinted photoresist material layer 102 to form a patterned photoresist layer 102 a. In the present embodiment, comprehensive irradiation is performed on the imprinted photoresist material layer 102 using a UV light 108. When the UV light 108 passes through the stamp 106 and is irradiated on the photoresist material layer 102, a cross-linking reaction can occur to the photoresist material layer 102 such that the photoresist material layer 102 is curied.

Next, referring to FIG. 1C, the stamp 106 is removed. At this point, the patterned photoresist layer 102 a is formed on the release layer 104, and the photoresist residue 102 b remains on the release layer 104 exposed by the patterned photoresist layer 102 a. Next, an adhesive layer 110 is formed on the top surface of the patterned photoresist layer 102 a. In the present embodiment, the adhesive layer 110 is, for instance, formed on the top surface of the patterned photoresist layer 102 a via a spray coating process. The adhesive layer 110 can be a regular adhesive layer removed via a method of applying a mechanical force (such as artificial peeling) in a subsequent process. Alternatively, the adhesive layer 110 can be a thermal-sensitive adhesive layer for which the adhesion is significantly reduced such that the adhesive layer 110 is readily removed when heated to high temperature (such as greater than 100° C.) by UV irradiation, laser irradiation, or infrared heating.

Next, the carrier substrate 100 on which the patterned photoresist layer 102 a is formed is adhered to a dielectric substrate on which a circuit pattern is formed. Details are provided below.

Referring to FIG. 1D, a circuit pattern 114 is formed on a dielectric substrate 112. The material of the dielectric substrate 112 is, for instance, epoxy resin, glass fiber cloth, or ceramic. The material of the circuit pattern 114 is, for instance, copper. Next, a dielectric layer 116 is formed on the dielectric substrate 112. The dielectric layer 116 covers the circuit pattern 114 on the dielectric substrate 112. The material of the dielectric layer 116 is, for instance, epoxy resin. The dielectric layer 116 is, for instance, formed on the dielectric substrate 112 via a lamination method. Next, an opening 118 exposing a portion of the circuit pattern 114 is formed in the dielectric layer 116. The forming method of the opening 118 includes, for instance, performing laser drilling or mechanical drilling. In the present embodiment, after the opening 118 is formed, a conductive seed layer 120 is formed on a portion of the circuit pattern 114 exposed by the opening 118 and on the dielectric layer 116. The material of the conductive seed layer 120 is, for instance, copper.

Next, referring to FIG. 1E, the adhesive layer 110 is adhered to the conductive seed layer 120 via precision alignment in a direction that the adhesive layer 110 faces the dielectric layer 116. By adhering the adhesive layer 110 to the conductive seed layer 120, the patterned photoresist layer 102 a is formed on the conductive seed layer 120 on the dielectric layer 116, and the region exposed by the patterned photoresist layer 102 a is the region in which a circuit pattern is subsequently formed. In the present embodiment, the patterned photoresist layer 102 a exposes a portion of the conductive seed layer 120 on the dielectric layer 116 and the opening 118.

Next, referring to FIG. 1F, the carrier substrate 100 is removed. In the present embodiment, since the release layer 104 is formed on the carrier substrate 100, the carrier substrate 100 can be readily separated from the patterned photoresist layer 102 a via the release layer 104. At this point, the photoresist residue 102 b remaining on the release layer 104 can also be removed. After the carrier substrate 100 and the patterned photoresist layer 102 a are separated, the patterned photoresist layer 102 a is formed on the dielectric layer 116, and the patterned photoresist layer 102 a is firmly formed on the dielectric layer 116 via the adhesive layer 110 below the patterned photoresist layer 102 a. As a result, even if the patterned photoresist layer 102 a has high aspect ratio, the patterned photoresist layer 102 a can still be firmly located on the dielectric layer 116 without falling or collapsing. In other words, in the present embodiment, the patterned photoresist layer 102 a can be firmly formed on the dielectric layer 116 via the adhesive layer 110, and therefore the selection of the photoresist material can be more flexible and the adhesion of the photoresist material is less influential. Next, a patterned metal layer 122 is formed on the conductive seed layer 120 exposed by the patterned photoresist layer 102 a. The material of the patterned metal layer 122 is, for instance, copper. The forming method of the patterned metal layer 122 includes, for instance, performing an electroplating process using the conductive seed layer 120.

Next, referring to FIG. 1G, the patterned photoresist layer 102 a is removed. The method of removing the patterned photoresist layer 102 a includes, for instance, performing a wet peeling process. Next, the adhesive layer 110 below the patterned photoresist layer 102 a is removed. As described above, when the adhesive layer 110 is a regular adhesive layer, the adhesive layer 110 can be removed via a method of applying a mechanical force (such as artificial peeling). Alternatively, when the adhesive layer 110 is a thermal-sensitive adhesive layer, after the patterned photoresist layer 102 a is removed, UV irradiation, laser irradiation, or infrared heating is performed on the adhesive layer 110 below the patterned photoresist layer 102 a to heat the adhesive layer 110 to high temperature (such as greater than 100° C.) such that the adhesion thereof is significantly reduced, and then the adhesive layer 110 is removed. In this way, the manufacture of a circuit board 10 of the present embodiment is complete. In the circuit board 10, the patterned metal layer 122 on the dielectric layer 116 and the conductive seed layer 120 below the patterned metal layer 122 form a circuit pattern 124, and the patterned metal layer 122 and the conductive seed layer 120 in the opening 118 form a conductive via connecting the circuit pattern 124 and the circuit pattern 114.

Second Embodiment

FIG. 2A to FIG. 2E are cross-sectional schematics of the manufacturing process of a circuit board shown according to the second embodiment of the invention. First, referring to FIG. 2A, a circuit pattern 202 a is formed on a first surface 200 a of a dielectric substrate 200, and a circuit pattern 202 b is formed on a second surface 200 b of the dielectric substrate 200. The material of the dielectric substrate 200 is, for instance, epoxy resin, glass fiber cloth, or ceramic. The material of the circuit patterns 202 a and 202 b is, for instance, copper. Then, a dielectric layer 204 a is formed on the first surface 200 a and a dielectric layer 204 b is formed on the second surface 200 b. The dielectric layer 204 a covers the circuit pattern 202 a on the first surface 200 a and the dielectric layer 204 b covers the circuit pattern 202 b on the second surface 200 b. The material of the dielectric layers 204 a and 204 b is, for instance, epoxy resin. The dielectric layers 204 a and 204 b are, for instance, respectively formed on the first surface 200 a and the second surface 200 b via a lamination method. Next, an opening 206 a exposing a portion of the circuit pattern 202 a is formed in the dielectric layer 204 a and an opening 206 b exposing a portion of the circuit pattern 202 b is formed in the dielectric layer 204 b. The forming method of the openings 206 a and 206 b includes, for instance, performing laser drilling or mechanical drilling. In the present embodiment, after the openings 206 a and 206 b are formed, a conductive seed layer 208 a is formed on a portion of the circuit pattern 202 a exposed by the opening 206 a and on the dielectric layer 204 a, and a conductive seed layer 208 b is formed on a portion of the circuit pattern 202 b exposed by the opening 206 b and on the dielectric layer 204 b. The material of the conductive seed layers 208 a and 208 b is, for instance, copper.

Next, referring to FIG. 2B, an adhesive layer 210 a is formed on the conductive seed layer 208 a and the adhesive layer 210 a seals the opening 206 a, and an adhesive layer 210 b is formed on the conductive seed layer 208 b and the adhesive layer 210 b seals the opening 206 b. The adhesive layers 210 a and 210 b can be thermal-sensitive adhesive layers for which the adhesion is significantly reduced such that the adhesive layers 210 a and 210 b are readily removed when heated to high temperature (such as greater than 100° C.) by UV irradiation, laser irradiation, or infrared heating. Next, a photoresist material layer 212 a is formed on the adhesive layer 210 a and a photoresist material layer 212 b is formed on the adhesive layer 210 b. In the present embodiment, the photoresist material layers 212 a and 212 b are photoresist material layers curied after UV irradiation, but the invention is not limited thereto.

Next, referring to FIG. 2C, an exposure process and a developing process are performed on the photoresist material layers 212 a and 212 b to form patterned photoresist layers 214 a and 214 b. Next, the adhesive layer 210 a exposed by the patterned photoresist layer 214 a is removed and the adhesive layer 210 b exposed by the patterned photoresist layer 214 b is removed. As described above, when the adhesive layers 210 a and 210 b are thermal-sensitive adhesive layers, UV irradiation, laser irradiation, or infrared heating is performed on the adhesive layer 210 a exposed by the patterned photoresist layer 214 a and the adhesive layer 210 b exposed by the patterned photoresist layer 214 b to heat the adhesive layers 210 a and 210 b to high temperature (such as greater than 100° C.) such that the adhesion thereof is significantly reduced, and then the adhesive layers 210 a and 210 b are removed. As a result, the patterned photoresist layer 214 a is formed on the conductive seed layer 208 a on the dielectric layer 204 a, and the region exposed by the patterned photoresist layer 214 a is the region in which a circuit pattern is subsequently formed. Moreover, the patterned photoresist layer 214 b is formed on the conductive seed layer 208 b on the dielectric layer 204 b, and the region exposed by the patterned photoresist layer 214 b is the region in which a circuit pattern is subsequently formed. In the present embodiment, the patterned photoresist layer 214 a exposes a portion of the conductive seed layer 208 a on the dielectric layer 204 a and the opening 206 a, and the patterned photoresist layer 214 b exposes a portion of the conductive seed layer 208 b on the dielectric layer 204 b and the opening 206 b. It should be mentioned that, the patterned photoresist layer 214 a is firmly formed on the dielectric layer 204 a via the adhesive layer 210 a below the patterned photoresist layer 214 a, and the patterned photoresist layer 214 b is firmly formed on the dielectric layer 204 b via the adhesive layer 210 b below the patterned photoresist layer 214 b. As a result, even if the patterned photoresist layers 214 a and 214 b have high aspect ratio, the patterned photoresist layer 214 a can still be firmly located on the dielectric layer 204 a without falling or collapsing, and the photoresist layer 214 b can still be firmly located on the dielectric layer 204 b without falling or collapsing. In other words, in the present embodiment, the patterned photoresist layer 214 a can be firmly formed on the dielectric layer 204 a via the adhesive layer 210 a and the patterned photoresist layer 214 b can be firmly formed on the dielectric layer 204 b via the adhesive layer 210 b, and therefore the selection of the photoresist material can be more flexible and the adhesion of the photoresist material is less influential.

Next, referring to FIG. 2D, a patterned metal layer 216 a is formed on the conductive seed layer 208 a exposed by the patterned photoresist layer 214 a, and a patterned metal layer 216 b is formed on the conductive seed layer 208 b exposed by the patterned photoresist layer 214 b. The material of the patterned metal layers 216 a and 216 b is, for instance, copper. The forming method of the patterned metal layers 216 a and 216 b includes, for instance, performing an electroplating process using the conductive seed layers 208 a and 208 b.

Next, referring to FIG. 2E, the patterned photoresist layers 214 a and 214 b are removed. The method of removing the patterned photoresist layers 214 a and 214 b includes, for instance, performing a wet peeling process. Next, the adhesive layer 210 a below the patterned photoresist layer 214 a is removed and the adhesive layer 210 b below the patterned photoresist layer 214 b is removed. As described above, when the adhesive layers 210 a and 210 b are thermal-sensitive adhesive layers, after the patterned photoresist layers 214 a and 214 b are removed, UV irradiation, laser irradiation, or infrared heating is performed on the adhesive layers 210 a and 210 b to heat the adhesive layers 210 a and 210 b to high temperature (such as greater than 100° C.) such that the adhesion thereof is significantly reduced, and then the adhesive layers 210 a and 210 b are removed. In this way, the manufacture of a circuit board 20 of the present embodiment is complete. In the circuit board 20, the patterned metal layer 216 a on the dielectric layer 204 a and the conductive seed layer 208 a below the dielectric layer 204 a form a circuit pattern 218 a, and the patterned metal layer 216 a and the conductive seed layer 208 a in the opening 206 a form a conductive via connecting the circuit pattern 218 a and the circuit pattern 202 a. Moreover, the patterned metal layer 216 b on the dielectric layer 204 b and the conductive seed layer 208 b below the dielectric layer 204 b form a circuit pattern 218 b, and the patterned metal layer 216 b and the conductive seed layer 208 b in the opening 206 b form a conductive via connecting the circuit pattern 218 b and the circuit pattern 202 b.

Although the invention has been described with reference to the above embodiments, it will be apparent to one of ordinary skill in the art that modifications to the described embodiments may be made without departing from the spirit of the invention. Accordingly, the scope of the invention is defined by the attached claims not by the above detailed descriptions. 

What is claimed is:
 1. A manufacturing method of a circuit board, comprising: providing a carrier substrate; forming a patterned photoresist layer on the carrier substrate; forming an adhesive layer on a top surface of the patterned photoresist layer; providing a dielectric substrate; forming a circuit pattern on the dielectric substrate; forming a dielectric layer covering the circuit pattern, wherein the dielectric layer has an opening exposing a portion of the circuit pattern; adhering the adhesive layer to the dielectric layer in a direction that the adhesive layer faces of the dielectric layer; removing the carrier substrate; forming a patterned metal layer on a region exposed by the patterned photoresist layer; removing the patterned photoresist layer; and removing the adhesive layer.
 2. The manufacturing method of the circuit board of claim 1, wherein the adhesive layer is removed by applying a mechanical force.
 3. The manufacturing method of a circuit board of claim 1, wherein a method of forming the patterned photoresist layer on the carrier substrate comprises: forming a photoresist material layer on the carrier substrate; performing an imprinting process on the photoresist material layer via a stamp; performing an exposure process on the imprinted photoresist material layer; and removing the stamp.
 4. The manufacturing method of the circuit board of claim 1, further comprising, after the dielectric layer is formed and before the adhesive layer is adhered to the dielectric layer, forming a conductive seed layer on a portion of the circuit pattern exposed by the opening and on the dielectric layer, and further comprising, after the adhesive layer is removed, removing the conductive seed layer below the adhesive layer. 